Laser level

Abstract

The present invention relates to laser leveling device suitable for construction. The present invention uses a standard low cost laser diode module as the laser source and optical system. A novel method is provided to align the non-collimated beam emitted from the standard low cost laser diode module so that it is perpendicular to the rotational axis of the laser level. The present invention describes a laser level which can be operated in four different modes: dot mode, line mode, oscillation mode and plane mode. Dot mode provides two level laser dots. Line mode provides a short bright level line. Oscillation mode provides a long bright reference line. Plane mode provides a level 360 degree reference plane. The invention also provides a structure which allows two vertical reference planes which are perpendicular to each other and perpendicular to the horizontal reference plane to be generated.

What is claimed: 
     
       1. A method of aligning a laser diode module, comprising: providing an alignment station with an alignment hole which is perpendicular to the earth;   providing a module housing, including: a cylindrical hole with a center axis, and   a main shaft which is perpendicular to the center axis;     providing a laser diode module that generates coherent light;   extending the main shaft into the alignment hole so that the main shaft is normal to the surface of the earth and defines a Z-axis of rotation;   defining an horizontal axis H which intersects and is perpendicular to the Z-axis of rotation and the center axis;   inserting the laser diode module into the cylindrical hole of the module housing, wherein the laser diode module is rotatable within the cylindrical hole;   spacing the alignment station from a vertical wall;   providing an alignment target on the vertical wall, wherein the alignment target includes a vertical reference line and a horizontal reference line, wherein the vertical reference line is normal to the earth and the horizontal reference line is perpendicular to the vertical reference line;   aligning the alignment station and the alignment target so that the horizontal reference line and the horizontal axis H are parallel to one another and in the same horizontal plane with respect to the earth;   powering the laser diode module so that a laser beam strikes the alignment target and causes a laser beam spot to appear on the target; and   rotating the laser diode module in the cylindrical hole of the module housing until the laser beam is centered along the horizontal reference line of the alignment target.   
     
     
       2. A method of making a laser system, comprising: providing a module housing, including: providing a cylindrical hole with a center axis, and   providing a main shaft defining an axis of rotation which is perpendicular to the center axis;     providing a case with a bearing to support the main shaft;   inserting the main shaft into the bearing;   providing a motor;   coupling the motor to the main shaft;   providing a rotatable laser diode module which generates coherent light;   inserting the rotatable laser diode module into the cylindrical hole in the module housing;   powering the rotatable laser diode module so that the rotatable laser module projects a laser beam along a center ray;   rotating the rotatable laser diode module until the center ray of the laser beam and the center axis define an angle θ, wherein the angle θ lies within a plane which is perpendicular to the axis of rotation of the main shaft.   
     
     
       3. A laser system, comprising: a module housing, including: main shaft defining an axis of rotation, and   a cylindrical hole with a center axis which lies in a plane perpendicular to the axis of rotation;     a case with a bearing to support the main shaft, wherein the main shaft is in the bearing;   a motor, wherein the motor is coupled to the main shaft; and   a rotatable laser diode module which generates coherent light, wherein the rotatable laser diode module is in the cylindrical hole of the module housing, wherein the rotatable laser diode module projects a laser beam along a center ray, wherein the center ray of the laser beam and the center axis define an angle θ, and wherein the angle θ lies within the plane which is perpendicular to the axis of rotation of the main shaft.   
     
     
       4. A laser system, comprising: a module housing, including: a first cylindrical hole with a first center axis, and   a second cylindrical hole with a second center axis, wherein the first and second center axis define a plane;   a main shaft defining an axis of rotation, wherein the axis of rotation is perpendicular to the plane;     a case with a bearing to support the main shaft, wherein the main shaft is in the bearing;   a motor, wherein the motor is coupled to the main shaft;   a first rotatable laser diode module which generates coherent light, wherein the first rotatable laser diode module is in the first cylindrical hole of the module housing, wherein the first rotatable laser diode module projects a first laser beam along a first center ray, wherein the first center ray of the first laser beam and the first center axis define a first angle θ, and wherein the first angle θ lies within the plane; and   a second rotatable laser diode module which generates coherent light, wherein the second rotatable laser diode module is in the second cylindrical hole of the module housing, wherein the second rotatable laser diode module projects a second laser beam along a second center ray, wherein the second center ray of the second laser beam and the second center axis define a second angle θ, and wherein the second angle θ lies within the plane.   
     
     
       5. The laser system of claim 3 or 4, further comprising an upper plate, secured to the case, including a first vial and a second vial, wherein the upper plate defines a shaft hole, a first vial hole, and a second vial hole, wherein the shaft hole is concentric with the Z-axis of rotation, the first vial hole defines a X-axis, and the second vial hole defines a Y-axis, and wherein the X- and Y-axis define a reference plane perpendicular to the Z-axis of rotation and the first vial hole houses the first vial and the second vial hole houses the second vial. 
     
     
       6. The laser system of claim 3 or 4, further comprising an upper plate secured to the case, wherein the upper plate defines a shaft hole concentric with the main shaft and a vial hole parallel to the shaft hole, wherein the vial hole houses a vial. 
     
     
       7. The laser system of claim 3 or 4, further comprising a bearing around the main shaft, a main pulley around the bearing, a free wheel attached to the main shaft and adjacent to the main pulley, wherein the main pulley and the free wheel each include at least one spaced apart magnet and the main pulley is coupled to the motor. 
     
     
       8. The laser system of claim 3 or 4, further comprising a rotatable cap having an opening and resting on the case, wherein the cap is coupled to the module housing and at least one laser beam is projected through the opening. 
     
     
       9. The laser system of claim 3 or 4, further comprising an upper plate secured to the case, a rotatable cap having an opening and resting on the upper plate, wherein the cap is coupled to the module housing and the laser beam is projected through the opening. 
     
     
       10. The laser system of claim 3 or 4, further comprising a rotatable cap having an opening, resting on the case, wherein at least one laser beam is projected through the opening, wherein the rotatable cap includes a spacing contact attached to the inner wall of the cap and impeding the rotation of the module housing. 
     
     
       11. The laser system of claim 3 or 4, further comprising an upper plate secured to the case, a rotatable cap having an opening and resting on the upper plate, wherein at least one laser beam is projected through the opening wherein the rotatable cap includes a spacing contact attached to the inner wall of the cap and impeding the rotation of the module housing. 
     
     
       12. The laser system of claim 2 or 3, further comprising a cross-hair accessory on the case, the accessory including a first mirror aligned to reflect the projected laser beam from a first direction perpendicular to the main shaft to a second direction parallel to the main shaft. 
     
     
       13. The laser system of claim 12, wherein the first direction is a rotating horizontal beam. 
     
     
       14. The laser system of claim 12, wherein the first direction is a rotating vertical beam. 
     
     
       15. The laser system of claim 12, wherein a plurality of cross-hair accessories are supported on the case. 
     
     
       16. The laser system of claim 3 or 4, further comprising an upper plate secured to the upper case, a cross-hair accessory secured to the upper plate, the accessory including a first mirror aligned to reflect the projected laser beam from a first direction perpendicular to the main shaft to a second direction parallel to the main shaft. 
     
     
       17. The laser system of claim 16, wherein the first direction is a rotating horizontal beam and the third direction is a vertical line perpendicular with respect to the horizontal beam. 
     
     
       18. The laser system of claim 16, wherein the first direction is a rotating vertical beam and the third direction is a horizontal line perpendicular with respect to the vertical beam. 
     
     
       19. The laser system of claim 16, wherein a plurality of cross-hair accessories are supported on the upper plate. 
     
     
       20. The laser system of claim 3 or 4, wherein the laser diode module includes: an outer casing with a shoulder;   a lens;   a power supply;   a laser diode; and wherein the outer casing houses the laser diode, the lens, and the power supply.     
     
     
       21. The laser diode module of claim 20, wherein the shoulder of the outer casing includes an outer edge with at least one ridge. 
     
     
       22. The laser diode module of claim 20, wherein the shoulder of the outer casing includes at least one hole. 
     
     
       23. A laser system, comprising: a module housing, including: a module hole, and   a main shaft defining a Z-axis of rotation;     a case with a bearing to support the main shaft, wherein the main shaft is in the bearing;   a motor, wherein the motor is coupled to the main shaft;   a laser diode module which generates coherent light, wherein the laser diode module is in the module hole, and wherein the laser diode module projects a laser beam along a center ray within a plane which is perpendicular to the axis of rotation of the main shaft;   an upper plate, secured to the case, including a first vial and a second vial, wherein the upper plate defines a shaft hole, a first vial hole, and a second vial hole, wherein the shaft hole is concentric with the Z-axis of rotation, the first vial hole defines a X-axis, and the second vial hole defines a Y-axis, and wherein the X- and Y-axis define a reference plane perpendicular to the Z-axis of rotation and the first vial hole houses the first vial and the second vial hole houses the second vial.